Removal Procedure
| Required Tools | |||
| Tool | Part Number | Part Description | Qty |
| A | 1U-7587 | Pry Bar | 1 |
Start By:
- Remove the valve mechanism cover. Refer to Disassembly and Assembly, "Valve Mechanism Cover - Remove and Install".
| NOTICE |
|---|
Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. |
| NOTICE |
|---|
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates. |
| Tools For Cleaning Carbon Deposits From The Injector Sleeve Bores | ||
| Part Number | Part Description | QTY |
| 4C-5027 | Tap Wrench | 1 |
| 4C-6161 | Tube Brush | 1 |
| 4C-6774 | Vacuum Gun Kit | 1 |
| 8T-7765 | Surface Reconditioning Pad | 1 |
| 1U-5512 | Cut & Polish Roll | 1 |
| 9U-6102 | Reamer | 1 |
| 9U-6862 | Tapered Brush | 1 |
| Tools For Evacuating Fuel From The Cylinders | ||
| Part Number | Part Description | Qty |
| 4C-4057 | Tube | 1 |
| 1U-5718 | Vacuum Pump | 1 |
| 169-7372 | Fluid Sampling Bottle | 1 |
Removal Of The Injector
 | |
| Illustration 1 | g00293685 |
(1) 128-6601 Solenoid Assembly (2) Harness Connector (3) Clamp (4) O-Ring Seals (5) 9Y-9025 Sleeve (6) Angled Seat (7) 137-5621 Tip Assembly | |
- Remove oil drain plugs (8) at each end of the cylinder head.
 | |
| Illustration 2 | g00865930 |
(8) Oil Drain Plug | |
- Allow the engine oil to drain from the ports in the cylinder head before the injector is removed.
 | |
| Illustration 3 | g00866097 |
(2) Wiring Harness Connection (3) Clamp (10) Shoulder Bolt (11) Socket Head Bolt | |
- Remove the harness connector (2) away from the injector solenoids.
- Remove the Shoulder Bolt (10) and the Socket Head Bolt (11) from the clamp (3) .
- Place Tooling (A) under the clamp (13) on the flywheel side of the injector.
 | |
| Illustration 4 | g00294212 |
 | |
| Illustration 5 | g00778851 |
(12) Do not pry here. (13) Tooling (A) should be placed at this location in order to gently remove the injector. | |
- Use Tooling (A) to remove the injector.
- Remove the O-Ring seals (4) from the injector.
 | |
| Illustration 6 | g00294208 |
(4) O-Ring Seals | |
- Repeat Step 3 through Step 7 for the remainder of the injectors.
Steps For Cleaning The Carbon Deposits
 | |
| Illustration 7 | g00778868 |
(14) Metal Seal | |
Cleanliness is very important in the area around the sleeve and the sleeve bore when you are reinstalling the injector. This injector has a metal seal between the bottom of the injector's case and a seat in the cylinder head. Unlike the former designs which were seated against a brass sleeve, this injector seats in the cylinder head. Clean the carbon from the seat area that is inside of the cylinder head. Also clean the carbon from the end of the injector if the injector should be reinstalled.
The fine grade of the Scotch Brite material is preferred. Scotch Brite is available from the Tools And Shop Products Guide as the 1U-5512 Cut & Polish Roll and as the 8T-7765 Hand Pad .
If the sleeve of the injector has been removed from the engine, use a 9U-6102 Reamer to remove carbon deposits from the angled surface.
Note: Do not use the 9U-6102 Reamer in order to remove metal from the sleeve. Use the 9U-6102 Reamer in order to remove carbon only.
If the sleeve of the injector is installed in the engine, use the 4C-6161 Tube Brush to clean the carbon deposits from the inside of the sleeve.
If you choose to clean the angled seat on the injector with a wire brush, the wire brush should not contact the tip of the injector. Failure of the tip and major engine damage may result.
Note: Using power tools in order to rotate the material should not be necessary. The carbon in the sleeve is more removable than the carbon at locations that are exposed to higher temperatures.
The following procedure is the preferred method of cleaning the sleeve bore.
- Place a 38 mm (1.5 inch) square piece of Scotch Brite material on the end of a 9U-6862 Tapered Brush.
- Twist the 9U-6862 Tapered Brush with the 4C-5027 Tap Wrench against the lower surface of the sleeve bore.
- The surface should be cleaned until the surface is smooth and shiny. The entire sleeve bore should be cleaned in order to remove any loose carbon particles.
Note: A 4C-6774 Vacuum Gun Kit is available in order to clean the loose material from the sleeve bore.
Evacuation Of Fuel And Oil From The Cylinder
Evacuate as much fuel and oil as possible from the cylinder before installation of the injector. Use the 1U-5718 Vacuum Pump, 169-7372 Bottle Assembly, and the 4C-4057 Tube to evacuate the fuel. Several evacuations may be necessary.